Airbag module with deployment control flap

ABSTRACT

An airbag module includes a bag wrap, a retainer, an airbag, and an inflator to inflate the airbag. The airbag includes at least one vent hole, and a deployment control flap to change trajectory of the airbag such that the airbag will deploy upwards and laterally to left and right sides. The deployment control flap is fixed at both ends to the retainer, airbag, or bag wrap.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application claims priority to U.S. Provisional Application Nos.:60/904,788, filed Mar. 5, 2007; 60/924,927, filed Jun. 5, 2007; and61/064,041 filed Feb. 12, 2008, all of which are incorporated herein byreference.

BACKGROUND

The present invention relates generally to the field of vehicle airbags.More specifically, the present invention relates to a vehicle mid-mountpassenger airbag with simplified construction and improved performance.

Vehicle airbags are used to protect vehicle occupants from injury in theevent of a vehicle crash. Current airbag designs incorporate a varietyof components that enhance the performance of the airbag: number andconfiguration of cushion folding techniques; deployment control panelsand delayer patch designs, or tethers; venting positions; and tear seamsincluded for the passive venting of the airbag.

SUMMARY

One exemplary embodiment relates to an airbag module including aretainer, an airbag, and an inflator to inflate the airbag. The airbagincludes at least one vent hole, and a deployment control flap to changetrajectory of the airbag such that the airbag will deploy upwards andlaterally to left and right sides. The deployment control flap is fixedat both ends to the retainer, airbag, or bag wrap.

Another embodiment relates to an airbag module including a retainer, anairbag, and an inflator to inflate the airbag. The airbag includes atleast one vent hole that is exposed early during inflation of the airbagand remains unblocked throughout inflation of the airbag; and adeployment control flap attached at both ends to the retainer that iswrapped around the outside of the airbag prior to deployment of theairbag.

Another embodiment relates to an airbag module including a retainer, anairbag, and an inflator to inflate the airbag. The airbag includes atleast one vent hole and a bag wrap to change trajectory of the airbagsuch that the airbag will deploy upwards and laterally to left and rightsides. The bag wrap includes a first portion and a second portion. Thefirst portion includes a first end fixed to the retainer. Theintersection of the first portion and second portion is attached to theairbag. The second portion is folded under and positioned between thefirst portion of the bag wrap and the airbag;

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a vehicle including an airbag and an adultoccupant according to an exemplary embodiment.

FIG. 2 is a side view of a vehicle including an airbag and a rear-facingchild seat according to an exemplary embodiment.

FIG. 3 is a side cross section view of an airbag module according to anexemplary embodiment in a folded or storage configuration provided in amid-mount position.

FIG. 4 is a side cross section view of the airbag module of FIG. 3 in afully inflated configuration.

FIG. 5 is a side cross section view of an airbag module according to anexemplary embodiment in a partially inflated configuration aftercontacting an obstruction such as a rear-facing child seat.

FIG. 6 is a top view of a deployment control flap for the airbag moduleof FIG. 3 according to one exemplary embodiment.

FIGS. 7A-7D are isometric views showing the deployment control flap ofFIG. 6 being folded according to an exemplary embodiment.

FIG. 8 is a top view of a portion of an airbag showing a passive ventingsystem according to an exemplary embodiment.

FIG. 9 is a top view of a delayer patch for an airbag module accordingto an exemplary embodiment.

FIG. 10 is a side cross section view of an airbag module according toanother exemplary embodiment in a folded or storage configurationprovided in a top-mount position.

FIG. 11 is a side cross section view of the airbag module of FIG. 10 ina fully inflated configuration.

FIG. 12 is a top view of a deployment control flap according to anotherexemplary embodiment.

FIG. 13 is a top view of a extension flap for an airbag module accordingto an exemplary embodiment, shown as being coupled to the center panelof the airbag cushion.

FIG. 14 is a side view of an airbag module with the center panel andextension panel of FIG. 13 shown in a deployed configuration.

DETAILED DESCRIPTION

An airbag is provided in vehicles for the protection of occupants in theevent of a vehicle crash. The airbag is configured to rapidly inflate ina space between the vehicle occupant and the vehicle dash, pillar, orother structure. Airbags are generally most effective when the occupantis restrained in the vehicle by a safety device such as a safety belt(e.g., an “in-position” situation). However, in some scenarios, anoccupant may not be restrained and may be closer to the vehicle dash orother structure during the vehicle crash (e.g., an “out-of-position”situation). In other scenarios, the vehicle may be occupied by a childin a child safety seat.

The embodiments described below allow for a low risk deployment of theairbag in a mid-mount configuration and provides a relatively lower costmeans of achieving the same performance in other configurations (e.g., ahigh-mount configuration). While the airbag mechanism is described belowas a dash-mounted airbag, it should be understood by those skilled inthe art that the inventive concepts may be applied to any suitableairbag and such airbags may be located in a variety of locations withinthe vehicle (e.g., a side curtain airbag, a seat-mounted side impactairbag, etc.).

The airbag includes an inflatable cushion and an inflator. The cushionis generally formed with at least two panels of a suitable material,such as nylon. The panels are coupled together with a sewn or woven seamto form at least one inflatable chamber. The cushion may be divided intotwo or more chambers. Passages or ports are generally between individualchambers such that the chambers are in fluid communication with eachother. The cushion is folded and concealed under a trim panel or othercovering (cover) in a storage position. The inflator, such as aconventional pyrotechnic inflator, supplies gas for inflation/deploymentof the restraint cushion. During a vehicle crash or rollover event, theinflator is activated to supply pressurized gas to inflate the cushion.The inflation gas enters the cushion and drives the airbag cushion awayfrom the storage position and into the deployed position. In thedeployed position, the cushion is disposed between the occupant and astructural member of the vehicle such as the vehicle dash. The airbagmay further include a bag wrap (e.g., cushion wrap) or other protectivecovering that surrounds the cushion in the storage position and as thecushion deploys.

If the vehicle seat is occupied by a child safety seat, the airbagcushion deployment is modified by a vent location and a deploymentcontrol flap (sometimes referred to as a “panel” or a “flap patch”). Inthe initial stage of deployment, the center of the deploying airbagcushion may be restricted by a deployment control flap, changing thetrajectory of the cushion such that the cushion may deploy upwardly andlaterally to the right and left sides rather than being directlyprojected at the center of a backrest of a child seat. The location ofthe vent holes can be determined by the fold(s) in the airbag. Ventholes are exposed early so should there be an obstruction, such as theforward edge of the backrest of a child seat in close proximity to thedeploying airbag which restricts deployment, gas escapes from exposedvent holes. Thus, the pressure escape can reduce deployment forces onthe child seat.

As the airbag cushion continues to deploy, the deployment control flapunfolds in the direction of the trajectory of the deploying cushion. Theinitially restricted center of the cushion follows the unfoldingdeployment control flap. As the deployment control flap unfolds andunfurls, the tear section, located proximate to the upper flap mounting,yields under the tension of the cushion on the flap. The yielding of thetear section then causes the restriction produced by the deploymentcontrol flap to be progressively removed, starting at the top and movingtoward the bottom. If the deployment control flap comes in contact withthe back of a high backed convertible child seat, the restriction on themain panel of the cushion at the bottom is largely maintained. As aresult, the bag trajectory is modified in a more upward direction. Inaddition to the backed traditional child seat, the flap will actuallyroll out over the child seat and the airbag trajectory will be modifiedin such that the deploying cushion trajectory passes above the childseat.

The airbag, in an embodiment, can utilize one or more vent holes to ventinflation gases. The vent holes can be X-vents, circular vents, or anyother type of vent holes. A vent hole can be positioned on a rightand/or left side panel of the airbag. The vent hole(s) can be locatedadjacent the throat of the airbag such that the vent holes are exposedearly in the deployment of the airbag cushion and remain unblockedthrough deployment of the airbag.

Reference will now be made to the FIGURES.

FIGS. 1 and 2 show a side view of a vehicle including an airbag module10 according to an exemplary embodiment. Airbag module 10 can be used asa driver's side airbag, a passenger airbag, side airbag, etc. Airbagmodule 10 can be used in a plurality of vehicles, including cars,trucks, vans, SUVs, buses, RVs, etc. Airbag module 10 may be mounted, asshown in the FIGURES, in the vehicle dash with a retainer 12 (FIG. 4).According to various exemplary embodiments, airbag module 10 may bemid-mounted on the dash, as shown in FIGS. 1-5, or may be top-mounted onthe dash, as shown in FIGS. 10-11, or the airbag module 10 may bemounted in any other suitable located in the vehicle. Airbag module 10is provided to protect an occupant 5 of the vehicle in a collision.

FIG. 3 illustrates an airbag module 10 according to an embodiment.Airbag module 10 includes an inflatable cushion 20, an inflator 30 toinflate cushion 20, a deployment control flap 40 to direct thedeployment of cushion 20, and a bag wrap 60 that surrounds and retainscushion 20 when the cushion 20 is in a storage configuration.

Cushion 20 is formed from a multitude of fabric panels, folded andconcealed under a trim panel or other covering in a storage position.According to one exemplary embodiment, cushion 20 is formed from atleast a center panel and two side panels. Alternatively, cushion 20 canbe a one-piece-woven airbag. Cushion 20 includes an opening or mouththat is coupled to a stationary object such as a mounting bracket andallows inflating gas from inflator 30 to enter cushion 20. Cushion 20further includes a throat portion 24 that is provided proximate to mouthand may include one or more vents 26, such as shown in FIG. 4.

Inflator 30, such as a conventional pyrotechnic inflator, supplies gasfor inflation/deployment of restraint cushion 20. During a vehicle crashor rollover event, inflator 30 is activated to supply pressurized gas toinflate cushion 20. The inflation gas enters the cushion 20 and drivescushion 20 away from the storage position (FIG. 3) and into the deployedposition (FIG. 4). In the deployed position, the cushion 20 is disposedbetween the occupant 5 and a structural member of the vehicle such asthe vehicle dash. A diffuser may be attached to the top and bottom ofthe throat 24 of cushion 20 and cause the gas produced by inflator 30 tobe directed laterally to the side panels of cushion 20. The airbagcushion 20 may further include a bag wrap 60 (e.g., cushion wrap) orother protective covering that surrounds cushion 20 in the storageposition and as the airbag cushion 20 deploys.

One end of deployment control flap 40 is coupled to airbag module 10 andredirects inflating cushion 20 in certain deployment scenarios.Deployment control flap 40 restricts, in the initial stage ofdeployment, the center of the deploying cushion 20, changing thetrajectory of cushion 20 such that the cushion 20 may deploy upwardlyand/or laterally to the right and left sides. As shown in FIG. 5, if theinflating cushion 20 contacts an out-of-position occupant 5 (e.g., anoccupant not wearing a seat belt or otherwise located too close to theinflating cushion, or a rear-facing child seat), deployment control flap40 redirects the direction of inflation of cushion 20 so the cushion 20is directed up and/or to the side rather than directly at the center ofa backrest of a child seat or out-of-position occupant.

Referring to FIG. 6, deployment control flap 40 is shown according toone exemplary embodiment. Deployment control flap 40 is an elongatedfabric panel that may be formed from the same material as airbag cushion20 (e.g., nylon) or any other suitable material. In one exemplaryembodiment, a first end 42 of deployment control flap 40 is coupled toretainer studs 14 that are provided to couple airbag module 10 to thevehicle. According to other exemplary embodiments, deployment controlflap 40 may be fixedly attached to the mouth of cushion 20 such as beingsewn to throat 24 of cushion 20. One or both ends 42, 44 may beattached/fixed to the retainer 12, retainer studs 14, cushion 20, orother component of the airbag module 10.

In one particular embodiment, deployment control flap 40 extends fromthe bottom of cushion 20, when cushion 20 is mounted to a vehicle dashin a mid-mount position. The length of deployment control flap 40 may bedependant upon the internal size of the vehicle and the mountingposition of the airbag cushion 20. The opposite end 44 of deploymentcontrol flap 40 is coupled to an upper cushion retainer mounting at thetop of cushion 20. Deployment control flap 40 includes a folded section46 and a separation or tear section 48 proximate to second end 44 asshown in FIGS. 6 and 7A-7D. Tear section 48 includes a tear-awaymechanism shown as a slit or cut 50 and one or more weakening features52 such as holes formed in deployment control flap 40. Slit 50 andfeatures 52 provide a weakened portion that allows tear section 48 torupture when inflating cushion 20 presses against deployment controlflap 40. The pressure needed to rupture tear section 48 and, therefore,the amount of time deployment control flap 40 restrains an inflatingcushion 20 may be modified by changing the size, number, and/or spacingof features 52 and/or slit 50.

Referring now to FIGS. 7A-7D, one exemplary operation is shown forcoupling a deployment control flap 40 to an airbag module 10 and of thefolding of the deployment control flap 40. As shown in FIG. 7A, a firstend 42 of deployment control flap 40 is coupled to airbag module 10. Asshown in FIG. 7B, second end 44 is brought around folded cushion 20,passed through a slot 64 in bag wrap 60, and coupled to airbag module10. According to an exemplary embodiment, second end 44 includes holes54 that are spaced apart to receive upper retainer studs 14. When secondend 44 is attached to airbag module 10, tear section 48 is generallyaligned with the top of folded cushion 20. According to other exemplaryembodiments, tear section 48 may be positioned proximate to first end42, second end 44, a central portion, or any other suitable location orlocations along the length of deployment control flap 40. Referring nowto FIG. 7C, deployment control flap 40 is pulled away from cushion 20 toeliminate slack and the excess length is folded until the folded flap 40lies against folded cushion 20. According to an exemplary embodiment, anaccordion fold is used so that deployment control flap 40 may deployquickly and smoothly. However, according to other exemplary embodiments,deployment control flap 40 may be otherwise folded. The foldeddeployment control flap 40 is stored proximate to the top of foldedcushion 20. As shown in FIG. 7D, bag wrap 60 is pulled around foldeddeployment control flap 40 and folded cushion 20 and fastened in place(e.g., by hooking to retainer studs 14).

Folding deployment control flap 40 in the manner shown in the FIGS.7A-7D determines the final position of vents 26 and the vent areaexposed. The vent location is moved closer to the throat 24 of airbagcushion 20 at a location where the vents 26 are exposed early on in thedeployment process. If the deploying cushion 20 contacts an object(e.g., an out of position occupant, a rear-facing child seat, etc.), asshown in FIG. 5, deployment control flap 40 directs the force of andinflation direction of cushion 20 upward and/or laterally. Because vents26 are exposed early, inflating gasses can escape cushion 20, reducingthe impact force on the occupant 5. The vents 26, in an embodiment,remain unblocked and exposed throughout inflation of the airbag cushion20.

Airbag assembly 10 is enclosed in a bag wrap 60 used to contain thefolds of various components of airbag module 10. A tear area 62 (FIG. 3)is located on bag wrap 60 to provide a weak point, so that during thedeployment of cushion 20, bag wrap 60 tears with minimum resistance. Afirst end 64 of bag wrap 60 is attached to the airbag cushion 20 and asecond end 66 of bag wrap 60 is attached to retainer studs 14.Alternatively, ends 64, 66 of the bag wrap 60 may each or both beattached to the retainer 12, retainer studs 14, airbag cushion 20, orany other suitable part of the airbag module 10.

FIG. 8 illustrates an embodiment with an internal guide panel 70including on or more tear seams for passive venting of gasses from theinterior of cushion 20. Passive venting allows airbag cushion vents 26to remain open during initial inflation and to close when airbag cushion20 is in its fully deployed state without the use of complicated orcostly controls. According to one exemplary embodiment, internal panel70 includes a first or open portion 74 and a second or closed portion76. Internal panel 70 is attached to cushion 20 with tear tabs 72 (e.g.,tear seams, etc.). During deployment, open portion 74 is aligned withopenings or vents in cushion 20. As cushion 20 fully deploys, tear tabs72 rupture and internal guide panel 70 is pulled such that closedportion 76 is aligned with the openings in cushion 20. The use of teartabs 72 reduces the variability of break out tension needed to breakstitches on demand. Tear tabs 72 can tear along a notched portion or inany other location when the airbag cushion 20 reaches a predetermineddeployment phase. The pull of cushion 20 on internal panel 70 duringdeployment rips or tears tabs 72.

For instance, upon deployment, if airbag cushion 20 contacts anout-of-position occupant or some other object (e.g., a rear-facing childseat 5), airbag cushion 20 is not capable of full inflation. In thisstate, it is necessary to allow the inflation gases to escape tominimize possible injury to the vehicle occupants. Open portion 74 isaligned with vents (not shown) in the airbag cushion 20 and gasses areallowed to escape the interior of cushion 20 through vents. However, ifairbag cushion 20 does not incur contact with an out of positionoccupant 5 or an object, the airbag is allowed to fully inflate andclosed portion 76 is aligned with vents. Passive venting may be used inaddition to deployment control flap 40.

FIG. 9 illustrates a delayer patch 80 for airbag cushion 20. The delayerpatch 80 is located internally within the airbag cushion 20 orexternally. Delayer patch 80 allows cushion 20 to deploy initially.According to the length of delayer patch 80, airbag cushion 20 willtravel the distance required for the system or environment to restrictthe initial effect of cushion 20, and therefore minimize injury to anoccupant. Delayer patch 600 may utilize one or more tear seams 82,similar to those described above for internal panel 70. The tear seams82 are configured to continue to tear away until airbag cushion 20reaches the distance required. Ends of the delayer patch 80 may beattached to the retainer 12, retainer studs 14, airbag cushion 20, orany other suitable airbag module component.

Referring to FIG. 10, an airbag module 110 is shown according to anotherexemplary embodiment. Module 110 is similar to module 10 and includes aninflatable cushion 120, an inflator 130 to inflate cushion 120, adeployment control flap 140 to direct the inflation of cushion 120, anda bag wrap 160 that surrounds and retains cushion 120 when the cushion120 is in a storage configuration. However, in this embodiment,deployment control flap 140 and bag wrap 160 are provided as oneintegrally formed body.

A tear area 162 is located on bag wrap 160 to provide a weak point, sothat during the deployment of airbag assembly 110, bag wrap 160 tearswith minimum resistance. Bag wrap 160 is coupled to the airbag module110 (e.g., sewn to cushion 120, coupled to retainer studs, etc.) at afirst end 164. Bag wrap 160 has a length that is extended to second end166 and folded to form deployment control flap 140. Second end 166 isattached to the other end of the airbag module 110 (e.g., hooked toretainer studs 114, sewn to cushion 120, etc.). Deployment control flap140 is contained between the folded cushion 120 and bag wrap 160.According to an exemplary embodiment, an end 144 of deployment controlflap 140 is free and not attached to airbag module 110. Thus, thedeployment control flap 140 is the portion of material of the bag wrap160 from the folded over portion at second end 166 to the end 144.

The integration of the bag wrap 160 and deployment control flap 140,allows for the containment of the folded cushion 120 while eliminatingone sew operation, i.e., the deployment control flap 140 being sewn toairbag cushion 120.

Referring to FIG. 11, the deployment of airbag assembly 110 isillustrated. As airbag cushion 120 inflates, bag wrap 160 releases attear area 162, and bag wrap 160 and deployment control flap 140 unrollto allow airbag cushion 120 to further inflate.

Referring to FIG. 12, a deployment control flap 240 for an airbagassembly is shown according to another exemplary embodiment. Deploymentcontrol flap 240 incorporates tabs 243 and slots 245 configuration. Tabs243 and slots 245 provide a second fixed point of attachment for thedeployment control flap 240 and facilitate aligning deployment controlflap 240 to bag wrap (not shown). In-position timing and cushiontrajectory are important to dynamic performance and low risk deploymentschemes. Properly locating deployment control flap 240 helps to ensureproper in-position timing and cushion trajectory.

Referring to FIGS. 13 and 14, a center panel 321 of a cushion 320 isshown according to an exemplary embodiment. Center panel 321 is coupledto an extension panel 323 that extends from the cushion 320 closing seam325 at the rear side of the module to the forward side of the module.Extension panel 323 allows cushion 320 to be properly protected fromsharp edges, flash and breaks at the dashboard lid during deployment.Extension panel 323 may be configured as a deployment control panel todirect the cushion deployment trajectory.

It is important to note that the construction and arrangement of thecushion wrap and/or deployment control flap with additional features asshown in the various exemplary embodiments are illustrative only.Although only a few embodiments have been described in detail in thisdisclosure, those skilled in the art who review this disclosure willreadily appreciate that many modifications are possible (e.g.,variations in sizes, dimensions, structures, shapes and proportions ofthe various elements, values of parameters, mounting arrangements, useof materials, colors, orientations, etc.) without materially departingfrom the novel teachings and advantages of the subject matter recited inthe description. For example, elements shown as integrally formed may beconstructed of multiple parts or elements, the position of the elementsmay be reversed or otherwise varied, and the nature of number ofdiscrete elements or positions may be altered or varied. Othersubstitutions, modifications, changes and omissions may be made in thedesign, operating conditions and arrangement of the exemplaryembodiments.

1. An airbag module, comprising: a retainer with an upper portion havinga retainer stud and a lower portion having a retainer stud, the upperportion being above an inflator; a bag wrap; an airbag cushion, theairbag cushion including at least one vent hole; a deployment controlflap to change trajectory of the airbag cushion such that the airbagcushion will deploy upwards and laterally to left and right sides, thedeployment control flap being fixed at both ends to the retainer, airbagcushion, or bag wrap, wherein the deployment control flap is external tothe airbag cushion; and the inflator to inflate the airbag cushion,wherein as the deployment control flap unfolds, a tear section yieldsunder tension of the airbag cushion on the deployment control flap suchthat the tear section tears and a restriction caused by the deploymentcontrol flap is progressively removed, wherein the tear section islocated adjacent to a mounting portion adjacent an upper portion of theretainer.
 2. The airbag module of claim 1, wherein the airbag cushion isa mid-mount airbag or a top-mount passenger airbag.
 3. The airbag moduleof claim 1, wherein the at least one vent hole is located in a throatportion of the airbag cushion.
 4. The airbag module of claim 3, whereinthe at least one vent hole is exposed early during inflation such thatif the airbag cushion contacts an obstruction, gas can escape from theairbag cushion to release pressure in the airbag cushion.
 5. The airbagmodule of claim 1, wherein the deployment control flap unfolds in adirection of trajectory of the deploying airbag cushion.
 6. The airbagmodule of claim 1, wherein the deployment control flap is attached atone end to the retainer stud.
 7. The airbag module of claim 6, whereinan opposite end of the deployment control flap includes the tearsection.
 8. The airbag module of claim 1, further comprising a bag wrap.9. The airbag module of claim 1, further comprising an internaldiffuser.
 10. The airbag module of claim 9, wherein the internaldiffuser forces gas from the inflator laterally to sides of the airbagcushion such that the airbag cushion first inflates to lateral left andright sides.
 11. The airbag module of claim 1, wherein a middle portionof the deployment control flap includes accordion-type folds.
 12. Theairbag module of claim 1, wherein the deployment control flap is anextension of a center panel.
 13. The airbag module of claim 12, whereinthe flap extends from an airbag closing seam at a rear side of theairbag module to a forward side of the airbag module.
 14. The airbagmodule of claim 1, wherein the deployment control flap includes a taband slot and is attached to the bag wrap.
 15. An airbag module,comprising: a retainer; an airbag cushion, the airbag cushion includingat least one vent hole; a deployment control flap to change trajectoryof the airbag cushion such that the airbag cushion will deploy upwardsand laterally to left and right sides, the deployment control flap beingfixed at both ends to the retainer, airbag cushion, or bag wrap; aninflator to inflate the airbag cushion; and a bag wrap, wherein thedeployment control flap protrudes through a slit in the bag wrap. 16.The airbag module of claim 8, wherein the bag wrap is attached toretainer studs.